PM MODULE FOR EBG -POWAI PLANT

TEAM LEADER : J S PATIL

TEAM MEMBERS : M M KUNTE SBU 2

: K A SARPOTDAR SBU 1 / SBU C

: T M RAJAGOPALAN SBU 3

: RAVI MORE PTL

TEAM STARTED WORKING FROM01/12/2000

WILL ‘GO LIVE’ IN 1ST WEEK OF APRIL 2001

PMPMPlant MaintenancePlant Maintenance

FIFIFinancialFinancial

AccountingAccounting

COCOControllingControlling

AMAMFixed AssetsFixed Assets

Mgmt.Mgmt.

PSPSProjectProjectSystemSystem

WFWFWorkflowWorkflow

MMMMMaterialsMaterials

Mgmt.Mgmt.PPPP

ProductionProductionPlanningPlanning

HRHRHumanHuman

ResourcesResources

SAP Plant Maintenance

SDSDSales &Sales &

DistributionDistribution

QMQMQualityQuality

ManagementManagement

Major sub-functions: Equipment and spares tracking Maintenance work management Preventive maintenance planning Maintenance information analysis (PM-IS) Measurements

SAP Plant Maintenance

Equipment and spares tracking Functional Location (P&ID) data Equipment data Bills of Material Permits Equipment Tasklists (Standard jobs) Functional/Location Tasklists General Tasklists

SAP Plant Maintenance

Contents of a Functional Location

Functional locationmaster record

Location data

PM data

Multilingual texts

Equipment usage

Classification

Documents

Contents of an Equipment Master Record

Equipment master record

General data

Location data

PM data

Multilingual texts

Internal note

Equipment usage

Classification

Documents

Maintenance Work Management creation of maintenance orders planning scheduling release confirmation settlement completion

SAP Plant Maintenance

Process Flow in PM

PM OrganizationPM Organization

PM ObjectsPM Objects

PlantsPM PlannerWork Centers(Workshops)Capacities

PlantsPM PlannerWork Centers(Workshops)Capacities

FunctionalLocations

Equipment

Assemblies

FunctionalLocations

Equipment

Assemblies

Direct ordercreation

Direct ordercreation

CompletionInformationCompletionInformation

ResourcesMaterial Internal External Services Services

PM HistoryDowntimes

Costs ....

PM OrdersPM Orders

PM Reqts./Notifications(Malfunction

reports)

PM Reqts./Notifications(Malfunction

reports)

PM Planning (Maintenance and

inspection releases)

PM Planning (Maintenance and

inspection releases)

Types of Maintenance Orders Preventive maintenance orders released by PM

schedules at due dates Planned orders arising from maintenance

notifications (malfunctions and work requests) Unplanned orders created if immediate action is

required Standing (blanket) work orders

SAP Plant Maintenance

Basic Steps in Maintenance Processing

Malfunction, errorRequestActivity

Malfunction, errorRequestActivity

PM Notificationwhatwhenwheretechn. information breakdown

Creating the orderPlanning the task

whowhen, for how longwhat stepsaccount assignment resources

Executionmaterial issueprocuring PRTswork steps

Techn. informationbreakdowncausesobjects affectedactivities

PM History

Completion

Requesting amaintenance

Task

1111

Order

Completionconfirmation

Completion

22223333 4444

5555

66667777

8888

Plant PM Planning PM Workshop

Preventive Maintenance Planning Time based maintenance strategies Performance based strategies Counter based strategies Maintenance Tasklists (Standard jobs) Maintenance Plans Maintenance Order Scheduling

SAP Plant Maintenance

Maintenance Task List Structure

Strategy, maintenance planning group, work center, equipment

Allocation of maintenance packages

Work center, description, time,control key, external processingdata, maintenance packages

Task list header

Operation

Maintenancepackages

Operation, time, work center, description, control keySub-operation

Quantity, BOM item, item category, quantity unit

Quantity, category

Material

Maintenanceresources

Maintenance OrderMaintenance OrderMaintenance PlanMaintenance Plan

MAINTENANCE STRATEGY

MAINTENANCE STRATEGY

MAINTENANCE PACKAGES:

-Time based-Performance based

- Counter based

MAINTENANCE PACKAGES:

-Time based-Performance based

- Counter based

SCHEDULED CALLS

SCHEDULED CALLS

MAINTENANCE ORDERS

MAINTENANCE ORDERS

MAINTENANCE ITEMS

MAINTENANCE ITEMS

-FUNCT LOCATIONS -EQUIPMENT -ASSEMBLIES

-FUNCT LOCATIONS -EQUIPMENT -ASSEMBLIES

ACTIVITIES:ACTIVITIES:

-Equipment Tasklists-Function Loc. Tasklists-General Tasklists

-Equipment Tasklists-Function Loc. Tasklists-General Tasklists

Maintenance Strategy

Maintenance Strategy

MAINTENANCE SCHEDULE

MAINTENANCE SCHEDULE

Elements in Maintenance Planning

Maintenance information analysis Equipment breakdown Maintenance cost Like equipment analysis MTBF

SAP Plant Maintenance

Provides up to date cost figures for better maintenance decision making

Realtime information flows between PM and other systems

No software interfaces between plant maintenance (PM) system and other systems such as human resources, purchasing, payables, and payroll etc.

Eliminates the need to pull data from difference systems for reporting purposes

Lower software maintenance cost Lower software implementation cost

SAP Plant Maintenance - Benefits

Maintenance orders detailed description technical objects operations and sub-operations internal resources material list external resources schedule dates order header

SAP Plant Maintenance

for requesting a maintenance activity/task

for describing a maintenance activity that has alreadybeen performed - purely technical documentation

for describing the condition of a maintenance objectand the malfunction in particular

Definition of a Maintenance Notification

Malfunction report

Activity report

Maintenance request

Structure of a Maintenance Notification

date/time/reported by description PM object: functional location equipment assembly location data account assignment data breakdown/availability data

Activities

Maintenancetasks

damage locationdamagecause of damage

Notificationitems

Notification

activityperformed by

datestask description

PM Overview Diagram

Create Work Orders

Create Work Orders

NotificationsNotifications

PlannedWork Orders

PlannedWork Orders

Schedule WO’sSchedule WO’s

Parts/SuppliesParts/Supplies

Labor Labor

Preventive/PredictiveMaint. WO’sPreventive/PredictiveMaint. WO’s

Master Data Master Data

Close and Settle WOClose and Settle WO

ReportingReporting

Special ToolsSpecial Tools

Pre-defined work stepsPre-defined work steps

EmergenciesEmergencies

External ServicesExternal Services Material

RequisitionsMaterialRequisitions

ShopPapersShopPapers

Maintenance OrdersMaintenance Orders

NotificationsNotificationsVendorVendor

LocationsLocations

CostCost

SuppliesSupplies

PartsParts

PeoplePeople

PlantsPlants

Special ToolsSpecial Tools

Repair StepsRepair Steps

EquipmentEquipment

FactoryCalendarFactoryCalendar

PM Master Data

Planned Maintenance Order

Planned Maintenance Order

NotificationsNotifications

Emergency DemandEmergency Demand

MaterialAvailabilityMaterialAvailability

Stock ReservationsStock Reservations

Purchase RequisitionsPurchase Requisitions

Create Maint. OrdersCreate Maint. Orders

SafetyConsiderationsSafetyConsiderations

Capacity Demand(Labor)

Capacity Demand(Labor)

Special ToolsSpecial Tools

Special InstructionsSpecial Instructions

Delivery Schedule of Material/ServicesDelivery Schedule of Material/Services

Release the Maint. OrderRelease the Maint. Order

Schedule theMaint. Order1. Manual2. Automatic

Schedule theMaint. Order1. Manual2. Automatic

Material ReservationsMaterial Reservations

Requisitionto Purch. OrderRequisitionto Purch. Order

PP/ PMPP/ PM

Planning & Scheduling

OrderOrder

ProjectProject

AssetAsset

Completion confirmationCompletion confirmation

Invoice receiptInvoice receipt

Goods receiptGoods receiptPurchase ordersPurchase orders

Material issueMaterial issue

Externalprocessing

Externalprocessing

CostsCosts

Task listTask list

BOMBOMMaterialsMaterials

Maintenance Order Functions

Capacity planningCapacity planning

OperationsOperations

Work centersWork centers

Object listObject list

ObjectsObjects

Shop papersShop papers

Cost centerCost center

Planning

Execution

Settlement